Container construction



Nov. 4, 1969 R. G. wHARToN 3,476,279

CONTAINER CONSVTHUCTION Filed Oct. 26, 1967 2 Sheets-Sheet l lfra. l.

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CONTAINER CONSTRUCTION Filed Oct. 26, 1967 2 Sheets-Sheet 2 fx/VEA/Toe.HUBERT G. Makro/v 5y 7T Toe/Veys United States Patent O 3,476,279CONTAINER CONSTRUCTION Robert G. Wharton, Alhambra, Calif. (15903Ashgrove Drive, La Mirada, Calif.

Filed Oct. 26, 1967, Ser. No. 682,715 Int. Cl. B65d 9/12, 9/34 U.S. Cl.217-12 3 Claims ABSTRACT OF THE DISCLOSURE Background of the inventionAlthough knock-down or collapsible packing boxes, shipping containers,etc. have been disclosed in the past, (see for example, Patents1,602,818; 1,737,186 and 2,596,320) they have not been found entirelysatisfactory since they required a multiplicity of differently formed orfinished pieces of lumber, special locking means, often were not weathertight or dust proof, and were not sufficiently strong to withstand thehandling, accidental dropping, and rigorous treatment which suchshipping boxes often receive. They were expensive, required great carein their assembly and disassembly in order to render them useful, andhad other disadvantages which the present invention obviates. Forexample, the construction elements which are utilized in the presentinvention are precut (when stock lumber is used) in substantially equallengths, need not be cut on an angle or bias, and do not require theformation of mortises and tenons.

The construction disclosed hereinafter provides a simple, inexpensive,strong, rigid and durable container composed of three pars of identicalend components, side components and top components; each component of apair is symmetrical with respect to axes at right angles to each otherwhereby the various components can be used interchangeably, i.e. a topcomponent may form the bottom or the top of a container; the ends can beinverted or used at either end of the package and the side componentscan also be inverted or used for either side of the finished containeror shipping box. When wood is used as the construction material, onlythree or four stock elements need be employed, namely (1) sheetpaneling, such as laminated plywood, (2) rail lumber of uniformcross-section, each rail comprising a body of rectangular cross-sectionand an outstanding tongue, (3) frame lumber of uniform section having agroove running along one edge to receive a rail tongue, and cleats ofsubstantially the same rectangular section as the body of a rail. Thisstock lumber can be transversely cut into predetermined lengths Withoutthe formation of mortises or tenons, assembled in jigs, nailing machinesor presses and easily and economically connected by nailing or gluinginto the simple pairs of end, side and top components. It is to beunderstood that extruded artificial lumber (sawdust-resin compositionsand the like) can be used for rails, cleats and frames or each componentcan be press-formed from a suitable composition including thermosettingor thermoplastic resins. The selection of materials used in forming thecompoice nents may depend upon the size and conditions of temperature,humidity and use of the finished container.

Moreover, as previously indicated, the present invention provides acontainer which has smooth internal surfaces, this facilitatingpackaging and arrangement of contents. The unique interlocking of thecomponents, one with the other, provides a firm mechanical, frictionalgrip therebetween as well as the formation of labyrinthine seals whichprotect the contents of the container from the weather, dust, etc.

An object of this invention therefore is to disclose and provide asturdy, strong container construction adapted to protect contents duringrough handling of the container construction.

Another object of the invention is to disclose and provide such acontainer construction which is readily assembled and which is readilydisassembled for reuse as a container or for reshipping in disassembledknockdown form.

A further object of the invention is to disclose and provide a containerconstruction having a novel interlocking arrangement of pairs ofcontainer components to provide a weatherproof container.

A still further object of the invention is to disclose a novel containerconstruction utilizing three pairs of top, side` and end wallcomponents, each of said pairs being symmetrical and permittinginterchangeable use of the components of each pair.

A still further object of the invention is to disclose and provide acontainer construction which eliminates the use of nails or screws forassembly of the several components of the container construction.

Other objects and advantages of the present invention will be readilyapparent from the following description of the drawings in which anexemplary embodiment of the invention is shown.

ln the drawings:

FIG. 1 is a perspective view of a container construction embodying thisinvention.

FIG. 2 is a fragmentary enlarged sectional view taken in the Aplaneindicated by line lI--II of FIG. 1.

FIG. 3 is an enlarged fragmentary sectional view taken in the planeindicated by line III-III of FIG. 1.

FIG. 4 is an exploded perspective View of the container constructionshown in FIG. 1.

A container construction embodying this invention is generally indicatedat 10, FIG. 1, the container 10 being assembled and banded ready forshipping. In FIG. 4 it will be readily apparent that container 10comprises a pair of top container components 11, side Wall containercomponents 12 and end wall container components 14. Each of the pair oftop components 11 are virtually identical in construction, and forbrevity and clarity the same reference numerals will be applied to eachcornponent of the pair. Each pair of side and end wall components 12 and14 are generally similarly constructed and similar elements thereof willbe given similar referance numerals, those of the end wall bearing aprime sign.

The pair of top components 11 provide the top and bottom of thecontainer when it is disposed as shown in FIG. 1, the bottommostcomponent being referred to as a top component because the container maybe turned over or turned upside down without change in relationship tothe other components, method of assembly or disassembly.

Each top container component 11 comprises a rectangular flat panelhaving a smooth uninterrupted inner surface 16. Along outer peripheralmarginal edge portions of panel 15 are secured pairs of side and endframe elements 17 and 18, respectively. Frame elements 17 and 18 may besecured in abutting inter-relationship to edge surface margins of panelby any suitable means such as adhesives, bonding agents, nailing orscrews. Outer side faces of frame elements 17 and 18 are ush with thelongitudinal edges of panel 15. Each frame element 17 and 18 may includea longitudinal groove 19 opening or facing away from the inner surface16 of panel 1S. Ends of side frame elements 17 abut at 20 opposedsurface portions of end frame elements 18 and may be adhesively bondedthereto. The peripheral arrangement of frame elements 17 and 18 providesa framed opening into which may be received edge portions of panels 22and 22 of side and end wall components.

Each side wall component 12 may comprise a hat, rectangular panel 22 andlongitudinally extending parallel rail elements 23 secured thereto andspaced apart by end studs or cleats 24 also xed to the panels. Each railelement 23 includes a longitudinally extending outstanding tongue 25extending toward longitudinal side edges 26 of panel 22. Each tongue 25is inwardly and laterally spaced from edge 26 and lies in a planeparallel to panel 22. Each rail element 23 has a length slightly greaterthan the length of panel 22 to provide a rabbetted edge or recess 27 ateach end of component 12 sufficient to receive vertical edge portions ofpanel 22 of end wall components 14.

Each end Wall component 14 may comprise flat rectangular panel 22' andtransversely extending parallel rail elements 23 spaced apart by endstuds or cleats 24. Each rail element 23 includes a longitudinallyextending outstanding tongue 25 spaced inwardly from edge 26' of panel22 and lies in a plane parallel to panel 22'. Each end wall component 14differs from its corresponding counterpart side wall component 12 inthat flat panel 22 has a width such that a relatively Wide rabbettedrecess 27' is provided to receive and to interlock with cleat 24 of sidewall component 12. Thus as best shown in FIG- URE 3, each corner of thecontainer 10 is comprised of cleats 24 and 24 in abutment as at 31 andadjacent surface portions of rail elements 23 and 23 as indicated at 32,32'.

Each panel 15, 22 and 22 may be made of the same material such aslaminated plywood of selected thickness and number of laminationsdepending upon strength required for the panel. Other sheet, plate, orboard like material may be employed.

Each frame element 17 and 18 used in the construction of the pair of topcontainer components 11 may be identical and may comprise stock lumberof rectangular cross-section with a longitudinal groove formed in onelongitudinal edge face. Similarly, each rail element 23, 23' may be madeof stock lumber of selected rectangular cross-section in which theoutstanding tongue 25, 25 is provided. Each cleat 24, 24' may be made ofstock lumber having a cross-section similar to the stock lumber fromwhich the rail elements 2.3, 23' were formed. In end and side wallcomponents 12 and 14, end cleats 24, 24 are shown; it will be understoodthat in containers of substantial length that intermediate studs orcleats may be used between the end cleats for strength and rigidity.

Each of sheet panels 15, 22 and 22 may be secured to their respectiveframe and rail elements as by bonding by suitable glues or adhesives oras by nailing or by both. It should be noted that each of the components11, 12 and 14 are symmetrical with respect to axes at right angles toeach other and that each of the components may be interchanged for theother of the pair of components so that only three pairs of componentsare required to construct a container embodying this invention, eachcomponent including three stock elements, namely, a panel, railelements, and cleats.

Assembly of the container construction 10 is readily apparent from FIG.4 of the drawings. A top component 11 may be placed upon a supportingsurface and the side and end components 12 and 14 assembled with tongues25, 25' extending into grooves 19 and with the corner rabbetted edges27, 27 in assembly as shown in FIG. 3. Top component 11 may then beplaced in assembly with the upper tongues 25, 25 of the components 12and 14. Horizontal edges of panels 22, 22' may slidably contact theinner surfaces 16 of panels 15 of the top components 11 and verticaledges of panels 22 may slid'ably contact inner surfaces of rail elements23 and cleats 24. Vertical edges of panels 22 may contact inner edgesurfaces of panels 22. The assembled container 10 may then be securedfor shipping by employing metal band-like fasteners 34 at corners of thecontainer to secure cleats 24, 24' together in assembled relation.Fasteners 34 may be of well-known form and each may comprise ablendable, fiat elongated member having one or more teeth (not shown)struck from end portions thereof. The teeth at each end may be readilydriven into adjacent end cleats 24, 24'.

In addition to the fasteners 34 which secure together end and sidecomponents of the container for shipment, bands 35 may also be placedaround the box and over the top and bottom components 11 so as to secureall of the components of the entire container in assembled relation.Bands 35 may be of metal such as steel or may be of other suitablenonstretchable material such as rib-bons of iiber glass, plastic and thelike.

Disassembly of container construction 10 is readily and easilyaccomplished by cutting bands 35 and, if desired, removing fasteners 34at, at least, two adjacent corners of the container. In this instance,one of the top components can be removed by lifting to disengage grooves19 -with tongues 25, 25. Either one end or one side wall component maythen be removed. In shipment of certain articles, removal of a topcomponent and one of the end or side wall components is usuallysufficient to permit removal of the article from the container. Theseveral components need not be damaged during removal because of thereleasable self-interlocking features of construction described above.In the event a different article is to be reship-ped, the lwall and topcomponents may be readily reassembled. If it is desired to return thecontainer construction in knock-down form, it will be apparent thatafter cutting the bands 35 and removing al1 of the corner fasteners 34,the several parts of the box can readily be disassembled and arranged insuitable fashion to occupy minimum space for return shipment inknock-down or disassembled form. In such disassembled form the parts maybe readily held together by bands such as 35.

As ibest viewed in FIGS. 2, 3 and 4 it will be apparent that when thecontainer construction 10 is completely assembled, the interior of thebox is provided with smooth, continuous, uninterrupted, interior wallsurfaces. Articles shipped in such a container may be restrained frommovement by the placement within the container of suitable dunnage asspace filling and cushioning material including polystyrene, crushed orshredded paper, sponge material and the like. Because the entireinterior surfaces are uninterrupted and no obstructions are present inthe container construction, articles may be readily positioned withinthe container with assurance that the article will not be damaged bycontact with obstructions or sharp pieces of wood or cleats which mightpenetrate, bend, dent or damage the shipped article.

It should also be noted that container construction 10 provides aweatherproof, self-locking container construction. Around the peripheryof the top components 11, a tongue and groove construction provides thefirst part of a labyrinthne joint. Inwardly of frame and rail elements23 and 23' the longitudinal edge marginal portions of the panels formwith the frame element of the top container components 11 a furtherextension of the labyrnthine joint. Thus the connections between the topcomponents and the side and end components are virtually weatherproof,dustproof and dirtproof. The corner constructions also provide alabyrinth joint in the interlocking of the rabbetted recesses 27 and 27at the corners between the end and side components. The abutment betweenthe end face of the side frame element 17 and end frame element 18 issealed by a suitable adhesive when the top component 11 is constructed.

The panels 22, 22 thus interlock with the frame elements 17 and 18inwardly of the peripheral tongue and groove interlock between frameelements 17 and 18 and rail elements 23 and 23' respectively and providea rigid mechanical frictional double interlock which affords a strongsturdy container construction capable of `withstanding shock and impactforces imparted to the container during handling and in transit.

I claim:

1. A readily assembled and disassembled container structure comprising:

three -pairs of top, side and end wall components, each component of apair being symmetrical with respect to two axes at right angles to eachother;

each of the pair of top components comprising a rectangular panel havingframe elements secured in abutting relation to marginal edge portions ofone surface of the panel, each of said frame elements being providedwith a longitudinal groove opening away from the panel;

each of the pairs of side and end wall components comprising arectangular wall panel, a rail element secured to an outer surface ofsuch panel along each longitudinal edge portion thereof, each railelement being provided with a longitudinal tongue extending toward suchedge but spaced from said outer panel surface;

said tongue on said rail element being cooperably engageable with saidgroove on an opposed frame element of said top components; saidlongitudinal edge portion of said wall panels extending along the innersurface of said frame element of said top components into proximity withthe interior surface of said rectangular panel of said top componentswhereby said rail elements and said longitudinal edge portions of saidwall panels are interlocked in assembly and form a labyrinth-type sealwith said frame elements.

2. A container structure as stated in claim 1 wherein the rectangularwall panel of the pair of side wall cornponents is coextensive in lengthwith the longitudinal grooved frame element secured to a longitudinalmarginal portion of the panel of the top component; and the rectangularwall panel of each of the pair of end wall components is shorter inlength than the grooved frame element secured to transverse marginalportions of the panel of the top component and is adapted to extendbetween and position the panels of side wall components, when the railelements thereof are grasping the frame of a top component.

3. A container structure as stated in claim 2 wherein the rail elementof each of the pair of end wall components is longer than therectangular wall panel of such component and coextensive in length withthe grooved frame ,member secured to the cooperating marginal edgeportion of the top component.

References Cited UNITED STATES PATENTS 875,548 12/1907 Miller 217-121,602,818 10/1926 Geddes 217-12 2,939,601 6/1960 Evans et al. 217-123,144,951 8/1964 Knabe 217-12 XR RAPHAEL H. SCHWARTZ, Primary ExaminerU.S. Cl. X.R.

